Poster Presentation

Dr. Arno Eichberger, University of Technology Graz, Austria
Mr. Florian Woergoetter, MAGNA Steyr Fahrzeugtechnik AG&Co KG, Austria
Mr. Gunter Haberkorn, MAGNA Steyr Fahrzeugtechnik AG&Co KG, Austria
Mr. Bernhard Fellner, MAGNA Steyr Fahrzeugtechnik AG&Co KG, Austria

Abstract: Increasing demands for reduced development costs and timeframes have resulted in a growing need for numerical simulations to facilitate the vehicle development process. The use of simulations is shifting towards the early design phases, a practice also known as "frontloading." This reduces the need for expensive, complete-car prototypes. In order to realise a virtual side impact development a new process has been developed [1]. Within this development process the simulation models are verified with tests of growing complexity from component up to full vehicle system level. The key issue of this verification procedure is a novel sled test rig that enables the simulation of the full vehicle side impact tests [4], [5]. This sled test rig can be distinguished from state-of-the-art sled test rigs [2], [3] by its conception of mainly providing data for verification of the numerical occupant simulation rather than providing test results that prove the side impact performance of the car. Therefore, the main focus lies in a design that results in minimum effort and need for pretests, a high repeatability of the impact acceleration profiles, high flexibility for change of the test set-up and minimum test costs. The sled test rig consists of the following components: main sled (representing the full vehicle assembly), door sled (carrying the intruding car side structure) and seat sled (allowing a lateral seat motion. The functionality and components are discussed in detail.

Additionally, the work-flow of the validation of the virtual engineering is explained. Firstly, the results of a numerical FEM simulation of a full vehicle side impact are compared to a numerical simulation of sled test rig. Parameters of the sled test set-up are adjusted until kinematics and dummy injury responses match the full vehicle simulation. Afterwards, the parameters of the numerical sled simulation are directly transferred to the physical test set-up and the test is performed. A sufficient accordance between simulation and test verifies the full vehicle simulation or the simulation has to be reworked.

References [1]Eichberger A., Michbronn D., Wörgötter F., Fellner B. (2007): A Novel Virtual Development Process for Side Impact at Magna Steyr Based on Numerical Simulations Verified by Component Testing. Proc. 6th EUROSIM Conference, Ljubljana, Slovenia, 2007. [2]http://www.autoliv.com/alv/connect/Home/What+We+Do/Crash+testing/Testing+Capabilities dated 2.7.2007 [3]http://www.acts.de/competence/testing/crashsimulation.shtml dated 2.7.2007 [4]Rieser A.: Entwicklung eines Schlittens zur Simulation des PKW Seitenaufpralls. Diploma thesis, Graz University of Technology, Austria, 2004 [5]Hoislbauer B.: Inbetriebnahme und Kalibrierung einer Schlittenanlage für den Seitenaufprall. Diploma thesis, Graz University of Technology, Austria, 2004 [6]Wörgötter F.: Optimierung der Konstruktion und Untersuchung der Versuchseinflussparameter einer Seitenaufprallschlittenanlage. University of Applied Science Joanneum, Graz, Austria, 2005

Poster presentation: Vehicle safety